How Long Until Hydrogen Fuel is a Reality?

By Owais AliReviewed by Frances BriggsOct 13 2025

In 2025, breakthroughs in clean production, compact storage, and real-world applications are bringing hydrogen fuel from the lab to the power grid and reshaping its role in the global energy mix.

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The depletion of fossil fuels, rising greenhouse gas emissions, and growing energy demand have accelerated global efforts to develop sustainable energy alternatives. While solar, wind, hydro, and geothermal power have advanced significantly, their reliance on factors beyond our control limits the continuous supply of energy and large-scale fuel production.

Hydrogen promises to be the answer, with its high energy density, renewability, storage efficiency, and zero-emission profile. Research continues to focus on improving production technologies, enhancing storage and transport safety, and expanding applications to support sustainable energy systems.¹

Sustainable Hydrogen Production

When hydrogen burns, unlike petrol, diesel, or coal, it does not produce carbon dioxide, making it a clean fuel. However, these fossil fuels are needed to produce hydrogen, generating significant life-cycle emissions. Consequently, there is a large body of research exploring sustainable production methods to replace current approaches.

Hydrogen from Recycled Aluminum and Seawater

Recently, scientists at MIT have developed a sustainable method for producing hydrogen by reacting recycled aluminum with seawater using a trace amount of a gallium-indium (Ga-In) alloy. The Ga-In alloy removes the oxide layer from aluminum, enabling a rapid reaction that releases hydrogen and forms aluminum oxide, while seawater salts facilitate alloy recovery for reuse.

Life cycle analysis revealed carbon emissions of only 1.45 kilograms of CO₂ per kilogram of hydrogen, significantly lower than the 11 kg produced through conventional fossil fuel-based methods.

 Image Credit: Ole Dor/Shutterstock.com

The process also allows on-demand hydrogen generation, with potential applications in coastal fueling stations and portable systems. It yields valuable aluminum-based by-products such as boehmite and other alumina phases.

However, the process still depends on the continuous input of aluminum and the energy-intensive recycling of aluminum oxide back to aluminum, which can significantly affect energy balance, cost, and overall scalability. The system is currently at lab scale, and further research is still needed to assess economic feasibility in real-world conditions.²

Biomass-to-Hydrogen Conversion with SECLG

In another study, the University of Johannesburg researchers have developed a promising method for producing low-emission green hydrogen from sugarcane bagasse using Sorption-Enhanced Chemical Looping Gasification (SECLG).

This process achieves hydrogen yields of 62-69 % while generating minimal by-products, including tar (<1 g/nm³), carbon monoxide (5-10 %), carbon dioxide (<1 %), and nitrogen (<5 %).

The carbon gases are further captured by metal oxide oxygen carriers and sorbents, maintaining a continuous carbon capture cycle and outperforming conventional biomass gasification systems that emit large quantities of tar and CO₂.³

A mathematical model and Aspen Plus simulation of the SECLG process demonstrated its high energy efficiency and capability for internal carbon capture, reducing the need for extensive gas-cleaning systems and lowering operational costs.

Although further experimental validation and scale-up are required, SECLG represents a technically viable route toward decarbonizing energy-intensive sectors such as steel and cement manufacturing. Challenges such as sorbent degradation, ash handling, oxygen carrier stability, and solid material transport must be addressed before industrial use is possible.

The current findings are based on simulation models and lab-scale assumptions.³

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Emerging Applications

Hydrogen-Powered Aircraft

Airbus plans to use hydrogen fuel cells as the propulsion technology under its ZEROe program for future commercial aircraft, following cryogenic research and successful prototype testing.

The ZEROe aircraft will feature four electric propellers, each powered by a hydrogen fuel cell stack that converts hydrogen into electricity, emitting only water as a by-product and achieving near-zero carbon emissions when powered by renewable hydrogen.

To accelerate this development, Airbus recently signed a Memorandum of Understanding with MTU Aero Engines to jointly progress hydrogen fuel cell propulsion.

The collaboration combines Airbus’s expertise in hydrogen-powered aviation with MTU’s proficiency in propulsion systems to mature essential technologies, coordinate research strategies, and develop a commercial-ready hydrogen fuel cell engine, marking a significant milestone toward zero-emission aviation.^4,5

Remaining technical hurdles, including cryogenic hydrogen storage, fuel cell system weight, and thermal management, need to be overcome before this can be rolled out beyond the conceptual and early development stages. 

1,800-Mile Range Hydrogen-Powered Truck

Recently, the Hydrogen and Fuel Cell Technologies Office (HFTO) and the U.S. Department of Energy reported a milestone in hydrogen-powered transportation with the H2Rescue prototype truck, which set a Guinness World Record by traveling 1,806 miles on a single hydrogen fill.

The 33,000-pound vehicle, powered by Cummins Accelera hydrogen fuel cell technology and a 250 kW traction motor, achieves sustained speeds of 50–55 mph under diverse conditions while emitting zero carbon dioxide, compared to 664 pounds of CO₂ produced by an equivalent internal combustion vehicle.

Designed for emergency response and military use, the H2Rescue truck could, once fully developed, replace approximately 1,825 gallons of diesel fuel and reduce greenhouse gas emissions by 2.5 metric tons annually, demonstrating hydrogen’s viability as a sustainable solution for heavy-duty transport.⁶

However, emission reduction figures may vary based on duty cycles, vehicle load, and hydrogen production methods. Operational data from longer-term field use is still being evaluated. 

Lignin-Based Hydrogen Storage System

Storing hydrogen fuel remains a critical challenge due to its low volumetric density, high flammability, and the need for safe, efficient, and cost-effective containment methods.

To address this, an international research team led by scientists at Washington State University has developed a novel hydrogen storage method using lignin-based jet fuel. The team demonstrated that hydrogen can be chemically stored within lignin-derived jet fuel, a renewable liquid made from plant-based polymers, allowing high-density storage without pressurized systems.

This dual-purpose fuel functions both as a sustainable aviation fuel and a stable hydrogen carrier, enhancing safety and scalability. The process also uses agricultural waste, further reducing environmental impact.

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The researchers are working to further integrate AI-driven catalysts for optimized reaction efficiency and cost, potentially enabling large-scale, infrastructure-compatible hydrogen deployment and advancing zero-emission energy systems.⁷

Further research is needed to validate long-term storage stability, reaction reversibility, catalyst lifespan, and more. The technology is still in the early research stage. 

High-Pressure Tanks for Hydrogen Transport

Similar challenges complicate hydrogen transportation, as its low density and high flammability require specialized high-pressure or chemically stable systems for safe and efficient delivery.

To overcome these challenges, Quantum Fuel Systems LLC, in collaboration with OneH2 Inc., has developed a 930-bar hydrogen Type 4 cylinder designed for mobile refueling and high-pressure gas transport.

These composite cylinders are integrated into modular hydrogen trailers, which deliver large volumes of gaseous hydrogen to vehicles and industrial equipment without requiring onboard or on-site compression.

Each trailer features a configurable set of cylinders, each capable of storing up to 27 kilograms of automotive-grade hydrogen, resulting in a total trailer capacity of approximately 486 kilograms.

Certified under a U.S. Department of Transportation permit, the system incorporates OneH2’s patented cascading technology, which allows efficient hydrogen transfer and minimizes residual gas losses.⁸

Cost-effectiveness, maintenance requirements, trailer refueling speed, and integration with existing hydrogen refueling infrastructure are areas which need further research. 

Conclusion

Hydrogen offers a clean, high-density, and versatile energy alternative; however, challenges in its production, storage, and transport hinder its widespread adoption. As research progresses, these obstacles are being addressed, making hydrogen safer, more efficient, and increasingly viable for sustainable energy systems. 

As of this week, in a UK first, energy company Centrica has introduced a hydrogen blend into the energy grid, working towards a fully sustainably powered future.  

Ongoing advances in materials science, energy systems engineering, life cycle economics, and supportive policy will scaffold the development of hydrogen fuel technology. 

References and Further Reading

1. Hossain Bhuiyan, M. M., & Siddique, Z. (2025). Hydrogen as an alternative fuel: A comprehensive review of challenges and opportunities in production, storage, and transportation. International Journal of Hydrogen Energy, 102, 1026-1044. https://doi.org/10.1016/j.ijhydene.2025.01.033
2. None Aly Kombargi, Bao, B., Ellis, E., & Hart, D. P. (2025). Life-cycle assessment and cost analysis of hydrogen production via aluminum-seawater reactions. Cell Reports Sustainability, 100407–100407. https://doi.org/10.1016/j.crsus.2025.100407
3. Motsoeneng, L. G., Oboirien, B., & Lanzini, A. (2025). Sorption enhanced chemical looping gasification of biomass for H2 and transportation fuel production. Renewable Energy, 248, 123022. https://doi.org/10.1016/j.renene.2025.123022
4. Airbus. (2025). ZEROe: our hydrogen-powered aircraft. https://www.airbus.com/en/innovation/energy-transition/hydrogen/zeroe-our-hydrogen-powered-aircraft
5. Airbus. (2025). Airbus and MTU Aero Engines advance on hydrogen fuel cell technology for aviation. https://www.airbus.com/en/newsroom/press-releases/2025-06-airbus-and-mtu-aero-engines-advance-on-hydrogen-fuel-cell-technology
6. Hydrogen and Fuel Cell Technologies Office. (2024). Hydrogen-Powered Heavy-Duty Truck Establishes New Threshold by Traveling 1,800 Miles on a Single Fill. https://www.energy.gov/eere/fuelcells/articles/hydrogen-powered-heavy-duty-truck-establishes-new-threshold-traveling-0
7. Lipton, A. S., et al. (2025). In-situ dehydrogenation of lignin-based jet fuel: A novel and sustainable liquid organic hydrogen carrier. International Journal of Hydrogen Energy, 98, 1275-1282. https://doi.org/10.1016/j.ijhydene.2024.12.082
8. Nehls, G. (2025). Quantum Fuel Systems, OneH2 develop 930-bar hydrogen tanks. https://www.compositesworld.com/news/quantum-fuel-systems-oneh2-develop-930-bar-hydrogen-tanks

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